Marsilli is an Italian manufacturer of motor winding systems. At present, brushless motors (in structure, brushless motors and brushed motors have similarities, as well as rotors and stators, but the structure of brushed motors is opposite; the rotor of brushed motors is a coil winding, which is connected to the power output shaft, The stator is permanent magnet magnetic steel; the rotor of the brushless motor is permanent magnet magnetic steel, which is connected to the output shaft together with the housing, the stator is the winding coil, and the commutation brush used by the brush motor to alternately change the electromagnetic field is removed, so it is called The design of the brushless motor is facing a revolutionary stage. The traditional excitation coil motor has reached the highest efficiency, and the bottleneck is mainly due to the filling factor. Marsilli is working on developing open pole motor windings and pushing them to different markets, including automotive hybrid systems, brakes, and industrial automation, improving the efficiency of motors by as much as 20% -25% and reducing material costs.
These performance improvements mainly depend on the overall design of the motor and specific application areas, "The motor can have higher torque, higher efficiency, and higher material utilization. We can increase the number of fill factors through innovative winding concepts ... We will achieve the goal of smaller, lighter and more cost-effective materials, "said S. Kumar Rajasekhara, president of Marsilli North America.
Open windings can contain more turns in the same space to obtain higher motor torque, and also allow the use of larger diameter winding wires to allow the motor to obtain more current. The company staff explained: "The lamination design is used in the traditional closed stator, which increases the magnetic field area and reduces the cogging effect to achieve more winding turns."
Marsilli's two advantages in the motor winding process: at the same size, the energy density of the open-winding motor is higher; or when the required output power is the same, the size and weight of the open-winding motor are smaller, saving material.
Lower winding stress can also reduce material costs, allowing the use of lower-cost wires (thinner, less insulating enamel quality). In addition, the optimization of the wire length reduces the amount of copper used. The company personnel realized that: "The strength of the electromagnetic field generated by the motor is proportional to the number of winding turns, regardless of its length."
The new motor winding product line contains two different series of motor windings. One of the series is designed for single-phase DC motors, which can be wrapped around single-phase electrodes and assembled and connected. The other series is for applications on multiphase DC motors.
For single-phase motor windings, such as SX winding machines, the motor windings are uniquely wound, then installed on the lamination structure and electrically connected to the stator. Suitable for complex winding designs (such as dual-winding coils), the SX winding machine uses a clamp to clamp one end of the winding, and a specific mobile device to control the winding process of the winding.
Use the CX winding machine to connect the multi-phase electrode windings, use tools to align the two windings, and then the simple winding stage does not need to cut the wire between the electrodes.
Marsilli has now turned to the development of motors and starter generators for automobiles. Is this technology suitable for heavy commercial vehicles? Rajasekhara said: "Generally it is feasible, but it depends on the size of the motor. We are working on expanding the size of the wire on the winding and the size of the motor. It will also be used on motorcycles and off-road vehicles. "
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